基于田口法的钻井直驱永磁同步电机设计及优化

Design Optimization of Permanent Magnet Motor for Direct-drive Drilling Based on Taguchi Method

针对“三相电机+减速装置+钻具”系统存在的机组冗长、效率低及可靠性低等问题,研发了钻井直驱永磁同步电机。设计计算了电机关键部件;以效率和齿槽转矩为优化目标,开展了电机稳健参数优化,采用田口法开展了电磁优化设计,筛选影响效率和齿槽转矩的4个显著因子作为可控因子,利用正交表对优化参数及其水平进行试验,计算了优化参数对效率和齿槽转矩影响程度,得到最优参数组合;开展了优化后电机的空载与负载电磁仿真分析,研究了空载与负载下电机性能,验证了电机优化设计的合理性;计算了电机额定工况运行下的主要损耗及关键部件生热率,仿真分析了电机在有、无钻井液通入下的温度分布,进一步验证了电机设计的合理性。研究结论可为井下直驱电动钻具设计提供理论依据,也可为海洋油气及水合物钻采设备的创新提供技术支持。

Considering that the “three-phase motor + reducer + drilling tool” system is deficient for long unit, low efficiency and low reliability, the permanent magnet synchronous motor for direct-drive drilling was developed. The key components of the motor were designed and calculated. With the aim to optimize the efficiency and cogging torque, the motor robust parameters were optimized, and the Taguchi method was adopted for the optimum electromagnetic design. With four significant factors affecting the efficiency and cogging torque selected as the controllable factors, and based on the orthogonal table, the optimized parameters and their levels were tested. After calculating the degree at which the optimized parameters affect the efficiency and cogging torque, the optimal parameter combination was determined. The electromagnetic simulation analysis was conducted on the optimized motor under no-load and load to study the performance of the motor and verify the rationality of the optimized design of the motor. The main loss and heat generation rate of key components of the motor under rated operating conditions were calculated, and the temperature distribution of the motor with or without drilling fluid was simulated to further verify the rationality of the optimized design of the motor. The study results can provide a theoretical basis for the design optimization of downhole direct-drive electric motors for drilling, and a technical support for the innovation of offshore oil, gas and hydrate drilling and production equipment.